Over-molded flexible knee brace

Abstract

A fitted hinge brace for supporting a joint that employs a flexible over-molding over hinge arms. The over-molded hinge brace dynamically conforms to the shape of the wearer in real-time, working with the wearer's body to provide comfortable support. The hinge brace includes first and second cuffs with flexible over-molding formed over medial and lateral hinges. The medial and lateral hinges each include a hinge arm and a hinge plate with geared portion. The geared portions of the medial hinge plate of the first cuff fit between the geared portions of the medial hinge plate of the second cuff, and the geared portions of the lateral hinge plate of the first cuff fit between the geared portions of the lateral hinge plate of the second cuff.

We claim: 
     
       1. A hinge brace comprising:
 a first cuff with a first flexible over-molding formed over a portion of a first medial hinge and a first lateral hinge, wherein the first flexible over-molding is formed of a continuous, flexible material, and the first medial hinge comprises: a first medial hinge arm and a first medial hinge plate with geared portions, and the first lateral hinge comprises: a first lateral hinge arm and a first lateral hinge plate with geared portions; and 
 a second cuff with a second flexible over-molding formed over a portion of a second medial hinge and a second lateral hinge, wherein the second flexible over-molding is formed of a continuous, flexible material, and the second medial hinge comprises: a second medial hinge arm and a second medial hinge plate with geared portions, and the second lateral hinge comprises: a second lateral hinge arm and a second lateral hinge plate with geared portions, 
 wherein the geared portions of the first medial hinge plate fit between the geared portions of the second medial hinge plate, and the geared portions of the first lateral hinge plate fit between the geared portions of the second lateral hinge plate. 
 
     
     
       2. The hinge brace of  claim 1 , wherein the first cuff tapers in a direction from the first lateral hinge to the first medial hinge. 
     
     
       3. The hinge brace of  claim 1 , wherein the flexible material is selected from the group consisting of urethane, an ethyl-based material and an ester-based material. 
     
     
       4. The hinge brace of  claim 1 , wherein the first medial hinge, the first lateral hinge, the second medial hinge, and the second lateral hinge are formed of a rigid material. 
     
     
       5. The hinge brace of  claim 1 , wherein the first medial hinge arm, the first lateral hinge arm, the second medial hinge arm, and the second lateral hinge arm comprise strap points. 
     
     
       6. The hinge brace of  claim 5 , wherein straps are connected to the strap points. 
     
     
       7. A hinge brace comprising:
 a first cuff with a first flexible over-molding formed over a portion of a first medial hinge and a first lateral hinge, wherein the first medial hinge comprises: a first medial hinge arm and a first medial hinge plate with geared portions, and the first lateral hinge comprises: a first lateral hinge arm and a first lateral hinge plate with geared portions; and 
 a second cuff with a second flexible over-molding formed over a portion of a second medial hinge and a second lateral hinge, wherein the second medial hinge comprises: a second medial hinge arm and a second medial hinge plate with geared portions, and the second lateral hinge comprises: a second lateral hinge arm and a second lateral hinge plate with geared portions, 
 wherein the geared portions of the first medial hinge plate fit between the geared portions of the second medial hinge plate, and the geared portions of the first lateral hinge plate fit between the geared portions of the second lateral hinge plate, and 
 wherein the first medial hinge and the second medial hinge are attached to a first top hub and a first bottom hub between a first top hub plate and a first bottom hub plate, and the first lateral hinge and the second lateral hinge are attached to a second top hub and a second bottom hub between a second top hub plate and a second bottom hub plate. 
 
     
     
       8. The hinge brace of  claim 7 , further comprising padding. 
     
     
       9. The hinge brace of  claim 7 , wherein the first flexible over-molding and the second flexible over-molding are capable of conforming to the shape of a body part. 
     
     
       10. The hinge brace of  claim 7 , wherein the first cuff tapers in a direction from the first lateral hinge to the first medial hinge. 
     
     
       11. The hinge brace of  claim 7 , wherein the first flexible over-molding and the second flexible over-molding are formed of a continuous, flexible material. 
     
     
       12. The hinge brace of  claim 7 , wherein the first medial hinge, the first lateral hinge, the second medial hinge, and the second lateral hinge are formed of a rigid material. 
     
     
       13. The hinge brace of  claim 7 , wherein the first medial hinge arm, the first lateral hinge arm, the second medial hinge arm, and the second lateral hinge arm comprise strap points. 
     
     
       14. The hinge brace of  claim 13 , wherein straps are connected to the strap points. 
     
     
       15. The hinge brace of  claim 14 , wherein the straps are made of Velcro material.